U.S. patent application number 15/183348 was filed with the patent office on 2016-12-22 for mattress ventilating foundation and sleep system.
The applicant listed for this patent is Neven Sleep, LLC. Invention is credited to Randy Reynolds.
Application Number | 20160367037 15/183348 |
Document ID | / |
Family ID | 57543778 |
Filed Date | 2016-12-22 |
United States Patent
Application |
20160367037 |
Kind Code |
A1 |
Reynolds; Randy |
December 22, 2016 |
MATTRESS VENTILATING FOUNDATION AND SLEEP SYSTEM
Abstract
Embodiments of a mattress ventilation foundation and sleep
system are disclosed. Foundation embodiments typically may be
configured to provide ventilation to a supported mattress, for
example through an upper surface of the foundation allowing airflow
therethrough. Sleep system embodiments typically have a mattress
(which might be a ventilation mattress) atop such a ventilation
foundation, with airflow therebetween.
Inventors: |
Reynolds; Randy; (High
Point, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Neven Sleep, LLC |
Dallas |
TX |
US |
|
|
Family ID: |
57543778 |
Appl. No.: |
15/183348 |
Filed: |
June 15, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62175767 |
Jun 15, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47C 27/148 20130101;
A47C 27/001 20130101; A47C 27/15 20130101; A47C 27/142 20130101;
A47C 19/025 20130101; A47C 31/007 20130101; A47C 21/044 20130101;
A47C 21/048 20130101 |
International
Class: |
A47C 21/04 20060101
A47C021/04; A47C 27/00 20060101 A47C027/00; A47C 27/15 20060101
A47C027/15; A47C 27/14 20060101 A47C027/14; A47C 19/02 20060101
A47C019/02; A47C 31/00 20060101 A47C031/00 |
Claims
1. A mattress foundation comprising: a support structure; an
airflow unit; and a foundation cover for the support structure
comprising an upper surface; wherein the upper surface comprises an
air permeable element; wherein the foundation cover encases the
support at structure to form a hollow cavity; wherein the
foundation cover further comprises one or more port allowing fluid
communication between the hollow cavity and an outside environment;
wherein the airflow unit is configured to induce fluid flow between
the hollow cavity and the outside environment via the one or more
port; and wherein the airflow unit is located within the hollow
cavity.
2. A mattress foundation comprising: a support structure; an
airflow unit; and a foundation cover for the support structure
comprising an upper surface, and wherein the upper surface
comprises an air permeable element.
3. The foundation of claim 2 wherein the foundation cover encases
the support structure to form a hollow cavity; wherein the
foundation cover further comprises one or more port allowing fluid
communication between the hollow cavity and an outside environment;
and wherein the airflow unit is configured to induce fluid flow
between the hollow cavity and the outside environment via the one
or more port.
4. The foundation of claim 2, wherein the air permeable element
comprises one or more high airflow mesh fabric panels.
5. The foundation of claim 4, wherein the entire upper surface of
the foundation cover is formed of high airflow mesh fabric.
6. The foundation of claim 3, wherein the one or more port is
located on a bottom surface of the foundation cover.
7. The foundation of claim 2, wherein the airflow unit is located
within the support structure.
8. The foundation of claim 6, wherein the airflow unit is located
within the hollow cavity over the port.
9. The foundation of claim 2, wherein the airflow unit comprises a
HEPA filter.
10. The foundation of claim 2, wherein the airflow unit comprises a
climate control unit operable to cool or heat air.
11. The foundation of claim 3, wherein the cover is air impermeable
except for the upper surface and the one or more port.
12. A sleep system comprising a foundation as in claim 2 and a
mattress, wherein the mattress is located atop and in contact with
the foundation and wherein the mattress and foundation are in fluid
communication with each other.
13. The sleep system of claim 12, wherein the mattress comprises: a
mattress cover encompassing the mattress; wherein the mattress
cover comprises a bottom surface, and wherein the bottom surface
comprises a mattress air permeable member.
14. The sleep system of claim 13, wherein the mattress air
permeable member comprises one or more high airflow mesh fabric
panels.
15. The sleep system of claim 13, wherein the mattress cover
further comprises an upper surface, and wherein the upper surface
comprises a second mattress air permeable member.
16. The sleep system of claim 13 further comprising one or more
foam layers within the mattress cover; wherein the one or more foam
layers each comprises a plurality of vertical air pathways which
pass through the entire thickness of the corresponding foam
layer.
17. The sleep system of claim 16, wherein the mattress comprises a
plurality of foam layers; and wherein at least some of the vertical
air pathways in the foam layers align to provide continuous airflow
paths from the bottom surface of the mattress to an upper surface
of the mattress.
18. The sleep system of claim 17, wherein the foundation cover
encases the support structure to form a hollow cavity; wherein the
foundation cover further comprises one or more port allowing fluid
communication between the hollow cavity and the outside
environment; and wherein the airflow unit is configured to induce
fluid flow between the hollow cavity and the outside environment
via the one or more port.
19. The sleep system of claim 18, wherein the one or more port is
located on a bottom surface of the cover; and wherein the airflow
unit is located within the hollow cavity.
20. The sleep system of claim 19, wherein the airflow unit
comprises a HEPA filter; and wherein the airflow unit comprises a
climate control unit.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a non-provisional of and claims priority
to related U.S. provisional patent application Ser. No. 62/175,767
filed Jun. 15, 2015 and entitled "Mattress Ventilating Foundation
and Sleep System. This application also claims priority to U.S.
patent application Ser. No. 14/681,278 (entitled "Independent Foam
Spring Mattress" and filed Apr. 8, 2015), and to related
provisional patent application Ser. No. 61/977,989 (entitled
"Independent Foam Spring Mattress" and filed Apr. 10, 2014). All of
the above-cited priority documents are hereby incorporated by
reference for all purposes as if reproduced in their entirety to
the extent that they are compatible (e.g. not inconsistent) with
and/or do not directly contradict disclosure herein (e.g. the
explicit disclosure herein would always govern/trump in instances
of contradiction, inconsistency, or incompatibility).
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] For a more complete understanding of the present disclosure,
reference is now made to the following brief description, taken in
connection with the accompanying drawings and detailed description,
wherein like reference numerals represent like parts.
[0005] FIG. 1A is a schematic diagram illustrating an exemplary
sleep/bedding system, in which a mattress may be used atop one of
two possible ventilating foundation exemplary variants;
[0006] FIG. 1B is a schematic diagram illustrating an alternate
exemplary sleep/bedding system, in which a mattress may be used
atop one of two possible ventilating foundation exemplary
variants;
[0007] FIGS. 1Ca-1Cc illustrate a detailed embodiment of a
sleep/bedding system similar to that of FIG. 1B and having an
internal air input unit with optional HEPA filter and an access
panel, with FIG. 1Ca showing a side view, FIG. 1Cb showing an end
view (from the foot of the bed), and FIG. 1Cc showing a top
view;
[0008] FIGS. 1Da-1Dc illustrate a detailed embodiment of a
sleep/bedding system similar to that of FIG. 1B and having an
external air input unit with optional HEPA filter and an access
panel, with FIG. 1Da showing a side view, FIG. 1Db showing an end
view (from the foot of the bed), and FIG. 1Dc showing a top
view;
[0009] FIG. 1E illustrates a perspective view of an exemplary
sleep/bedding system similar to FIGS. 1Ca-1Cc;
[0010] FIGS. 2A1 and 2A2 illustrate an exemplary mattress
embodiment (without the cover being shown, to allow viewing of
internal components) which is an all-foam (e.g. spring-free)
mattress configured for ventilation, with FIG. 2A1 showing an
exploded perspective view of an exemplary mattress and FIG. 2A2
showing a cut-away (e.g. cross-section) elevation view of the
exemplary mattress of FIG. 2A1;
[0011] FIGS. 2B1 and 2B2 illustrate an exemplary mattress
embodiment (similar to that of FIG. 2A1 in configuration, but
comprising different foam materials for at least some of the
layers) configured for ventilation, with FIG. 2B1 showing an
exploded perspective view of an exemplary mattress and FIG. 2B2
showing a cut-away (e.g. cross-section) elevation view of the
exemplary mattress of FIG. 2B1;
[0012] FIG. 3 illustrates a top/plan view of an exemplary base
(sculpted) layer of foam (of the sort that might be used in FIG.
2A1, for example); and
[0013] FIG. 4 illustrates a bottom/plan view of an exemplary middle
sculpted foam layer (of the sort that might be used in FIG. 2A1,
for example).
DETAILED DESCRIPTION
[0014] It should be understood at the outset that although
illustrative implementations of one or more embodiments are
illustrated below, the disclosed systems and methods may be
implemented using any number of techniques, whether currently known
or not yet in existence. The disclosure should in no way be limited
to the illustrative implementations, drawings, and techniques
illustrated below, but may be modified within the scope of the
appended claims along with their full scope of equivalents.
[0015] The following brief definition of terms shall apply
throughout the application:
[0016] The term "comprising" means including but not limited to,
and should be interpreted in the manner it is typically used in the
patent context.
[0017] The term "foam" means a material in a lightweight cellular
form, for example resulting from introduction of gas bubbles during
manufacture to produce a consistent cell structure, and/or any of
various light, porous, semirigid or spongy materials or cellular
solids, usually the solidified form of a liquid full of gas
bubbles, which may be used as a building material or for shock
absorption, and includes open cell foams such as polyurethane foam,
latex, memory foam, specialty memory foam, gel memory foam, gel
latex foam or other gel foams, etc.;
[0018] The term "IFD" means indentation force deflection, and
describes a well-known measurement system for foam firmness;
[0019] Directions, such as up (e.g. upward) and/or down (e.g.
downward), typically are intended to be based on the mattress (or
sleep system or foundation) in its normal sleeping position as
understood by persons of skill; for example, the upper surface of
the mattress might face the ceiling and/or serve as the sleep
surface upon which the user might lie, while the bottom surface of
the mattress might face the floor or ground and/or be placed atop a
foundation;
[0020] The phrases "in one embodiment," "according to one
embodiment," and the like generally mean that the particular
feature, structure or characteristic following the phrase may be
included in at least one embodiment of the present invention, and
may be included in more than one embodiment of the present
invention (importantly, such phrases do not necessarily refer to
the same embodiment);
[0021] If the specification describes something as "exemplary" or
as an "example," it should be understood that refers to a
non-exclusive example:
[0022] The terms "about" or "approximately" or the like, when used
with a number may mean that specific number, or alternatively, a
range in proximity to the specific number, as understood by persons
of skill in the art field (for example, +/-10%); and
[0023] If the specification states a component or feature "may,"
"can," "could", "should," "would," "preferably," "possibly,"
"typically," "optionally," "for example," "often," or "might" (or
other such language) be included or have a characteristic, that
particular component or feature is not required to be included or
have the characteristic. Such component or feature may be
optionally included in some embodiments, or it may be excluded.
[0024] Typical sleep or bedding systems may have a conventional
(typically inner-spring) mattress located atop a conventional box
spring foundation unit. In such conventional sleep systems, there
is typically no interaction between the mattress and the box spring
foundation, other than the fact that the box spring foundation
supports (e.g. underlies) the mattress. While conventional sleep
systems may be sufficient for some sleepers/users, many users might
desire and are looking for an improved sleep experience.
[0025] For example, many users might find conventional sleep
systems rather hot (especially when the mattress includes foam, and
most especially when the mattress includes memory foam), resulting
in a rather sweaty, uncomfortable night's sleep of the sort that
may result in restlessness and lack of deep slumber. Other users
may have allergy problems, and a conventional mattress may, over
tune, collect dust and other allergens that might trouble the user
during sleep. Additionally, conventional inner-spring mattresses
may not support the user's body as effectively as desired, perhaps
resulting in discomfort.
[0026] The presently disclosed embodiments may address one or more
of these issues. For example, disclosed embodiments may provide
ventilation (e.g. airflow), such that the mattress may better
breathe and/or disperse heat (e.g. improving sleep comfort while a
user is atop the mattress); disclosed embodiments may refresh the
mattress, for example sucking out stale air with potential
allergens (which could happen either when the user is atop the
mattress or, alternatively, when the user is not on the mattress
(for example, based on a timer)); and/or disclosed embodiments may
provide superior comfort/support. Typically, disclosed embodiment
sleep systems might have the mattress and foundation interact with
each other (for example, being in fluid communication), to provide
one or more such sleep benefits, as persons of skill will
understand based on the disclosure below. Typical foundation
embodiments might comprise an upper surface (of a cover) allowing
airflow therethrough (and typically having an airflow unit (such as
a fan or air pump) operable to direct air through the upper
surface), while typical mattress embodiments might comprise a
bottom surface (of a cover) (and in some embodiments, a top surface
of the cover) allowing airflow therethrough (and often also
including air pathways (such as pinholes) vertically throughout the
mattress). So, most disclosed sleep system embodiments typically
might have a ventilation mattress atop a ventilation foundation,
with airflow therebetween.
[0027] Disclosed embodiments relate generally to mattress
ventilation sleep systems (and/or related foundations and/or
mattresses), which typically would include a mattress ventilation
foundation in conjunction with a mattress (for example, typically
located atop the foundation). Typically, the mattress ventilation
foundation might comprise a support structure (such as support
struts and structural frame, for example, which might be similar to
a conventional box spring foundation), operable to support a
mattress in a manner similar to a conventional mattress foundation
(and which typically might be hollow); an airflow unit (such as a
forced air supply unit (e.g. fan) operable to either blow air into
the supported mattress atop the foundation or suck air from the
supported mattress); and a cover (including an upper, support
surface upon which the mattress would lay), which would typically
include a means for airflow between the foundation (e.g. the
airflow unit) and the supported mattress (e.g. an air permeable
element/panel, such as one or more panels of high airflow mesh
fabric located in the upper surface of the foundation cover, for
example). In some embodiments, the airflow unit might include
filtration (such as a HEPA filter), which might, for example, be
located at the intake and/or outtake for the airflow unit. The
airflow unit might be housed within the support structure of the
foundation (e.g. within the hollow cavity) in some embodiments,
while in other embodiments the airflow unit might be external to
(for example, mounted onto) the support structure (for example,
mounted onto the bottom surface of the cover/support structure and
in fluid communication with the hollow cavity within the
cover/support structure by an opening).
[0028] Typically, the foundation cover would
surround/enclose/encompass the support structure on all sides, and
the foundation cover would be airtight/air impermeable (e.g. formed
of an airtight material, such as fabric overtop a polyvinyl
substrate, for example) except for the attachment/fluid
communication port (e.g. inlet/outlet/opening) for the airflow unit
(which allows fluid communication between the external environment
and the hollow cavity within the foundation, for example) and the
means for airflow between the foundation and the supported mattress
(e.g. air permeable element/panel, such as high airflow mesh
panel(s)). For example, the bottom and side surfaces of the
foundation cover would typically be airtight (except for the
inlet/outlet/opening for the airflow unit), while the upper surface
of the foundation cover which would typically support and/or
contact the bottom surface of the mattress) would include the means
for airflow between the foundation (e.g. the airflow unit) and the
supported mattress (e.g. at least one air permeable element/panel,
such as one or more panels of high airflow mesh fabric located in
the upper surface of the foundation cover, for example). In some
embodiments, the entire upper surface of the foundation cover might
be formed of high airflow mesh fabric, while in other embodiments,
the upper surface might include a plurality of panels of such high
airflow mesh fabric and/or other means for allowing airflow between
the foundation and the supported mattress (such as air
passageways). While some embodiments might have a cover that
encompasses substantially the entire support structure, other
embodiments might have a cover that only spans the upper surface of
the support structure, while still other embodiments might have a
cover which spans the upper surface and a portion or all of the
vertical sides of the support structure.
[0029] Typically, air might flow through the hollow cavity of the
foundation to the upper surface of the foundation cover (as
directed by the airflow unit, for example), but alternatively,
there could be tubing or ducts leading from the airflow unit to the
upper surface of the foundation cover (e.g. specific locations on
the upper surface of the foundation cover corresponding to the
pinholes in the supported mattress thereupon). In such embodiments,
it might not be necessary for the bottom and sides of the
foundation cover to be airtight.
[0030] Additionally, some embodiments of the airflow unit might
optionally comprise a climate control unit, which might cool and/or
heat air flowing through the airflow unit (for example, before the
air flows into the supported mattress atop the foundation). In some
embodiments, the climate control unit would be located within the
housing for the airflow unit, while in other embodiments, the
climate control unit might be located external to such housing
(e.g. it may be either separate or combined with the blower portion
of the airflow unit). Similarly, embodiments of the airflow unit
might optionally comprise an air ionizer (for electric
sterilization of air prior to entering the foundation) and/or an
ultraviolet germicidal irradiation light (for irradiating light
sufficiently to substantially destroy harmful microbes, such as
bacteria, prior to entering the foundation). As with the optional
climate control unit, the air ionizer and/or UV germicidal
irradiation light units could be located within the housing for the
airflow unit or (in other embodiments) located externally to such
housing (e.g. each may be either separate or combined with the
blower portion of the airflow unit). Typically, the airflow unit
might be controlled/operated by a controller, which might be a
separate device and which might allow for remote control of the
airflow device (e.g. the blower and/or climate control unit). In
some embodiments, the controller and/or airflow unit may include a
timer, for example, allowing the user to set the airflow unit for a
regular (for example, daily or weekly) refresh cycle. And
typically, the airflow unit would be electrically powered (for
example, with a plug allowing power to be drawn from a standard
electrical wall socket).
[0031] So, typically in operation, air might be drawn into the
foundation (for example, by the airflow unit, through the intake
opening/fluid communication port), and then forced out the upper
surface (for example, through a high airflow mesh fabric upper
surface or panel(s)) and into the supported mattress. This may
allow for a supported mattress to be refreshed with clean air
and/or may enhance sleep comfort for a user lying atop the
mattress. Alternatively, air might be sucked out of the supported
mattress (for example, by operating the airflow unit in reverse to
create suction), into the foundation (for example, through the
upper surface of the cover of the foundation, perhaps through one
or more high airflow mesh panels), and out the airflow unit's
outtake opening/fluid communication port (which might be the same
intake opening if the airflow device is operated for blowing
instead of suction in some embodiments). In some embodiments, the
airflow unit might be operable to run in forward (e.g. blowing
mode) and/or reverse (e.g. suction mode). So, in some embodiments,
the airflow unit might be run in reverse (for example, suction mode
to suck air from the supported mattress) to refresh the mattress
(e.g. a refresh cycle, which in some embodiments might be
periodically run), while the airflow unit might be run in forward
(for example, blowing mode to blow fresh (e.g. filtered) and/or
climate controlled (e.g. cooled or heated) and/or ionized and/or UV
sanitized air into the supported mattress) to enhance sleep comfort
atop the supported mattress (for example, improving allergy
conditions and/or temperature and/or airflow for the user atop the
supported mattress, perhaps while the user is actually lying
atop/sleeping on the mattress).
[0032] While it is possible that any sort of mattress might be used
to some advantage atop such a ventilation foundation, more
typically specialized air flow (e.g. ventilation) mattress
embodiments might be used in conjunction with the disclosed
foundation embodiments. For example, the mattress might comprise a
mattress cover having a bottom surface which includes a means for
airflow between the foundation and the supported mattress (e.g.
into and/or out of the mattress, for example at least one air
permeable member/element/panel). For example, in some embodiments,
the bottom surface of the mattress cover might be formed of or
include one or more panels of high airflow mesh fabric (or
alternatively, the bottom surface of the mattress cover might
include air passageways, which might correspond to those of the
upper surface of the foundation cover). In some embodiments, the
top surface of the mattress cover might also comprise air permeable
member/element/panel or other means of airflow into/out of the
mattress (e.g. high airflow mesh or loosely woven fabric panel(s)).
And in some embodiments, the remainder of the mattress cover might
be (substantially) air impermeable. Furthermore, the mattress might
comprise one or more (and typically a plurality of) primarily
vertical air pathways (e.g. pinholes), operable to allow air flow
vertically throughout the mattress (for example, from the bottom of
the mattress to the top of the mattress). In some embodiments, the
mattress might be an all-foam and/or spring-free mattress. For
example, the mattress might be formed entirely of layers of foam,
and each layer of foam might include vertical pinholes, at least
some of which align to provide continuous airflow
passages/pathways/pinholes vertically throughout the mattress.
[0033] Some such mattress embodiments might include one or more
foam layers having a sculpted surface with a plurality of foam
pillars. For example, some embodiments might have a base layer of
foam (e.g. the bottom layer of foam) with an upward facing sculpted
surface (e.g. the pillars of foam facing/projecting upward), and
another layer of foam (typically a middle foam layer, located
somewhere between the base foam layer and the uppermost (sleep
surface) layer of foam) with a downward facing sculpted surface
(e.g. the pillars of foam facing/projecting downward). Typically,
the sculpted foam layers would each have scoring (e.g. a series of
grooves/gaps) forming a grid on one surface (termed the sculpted
surface), with the grid pattern resulting in a plurality of foam
pillars projecting outward from a common, unified slab/base of foam
(e.g. the surface opposite the sculpted surface typically would be
flat, such that the foam pillars would all be joined together into
an integral whole layer at their bases/bottoms). The sculpted foam
layer(s) might effectively replace the support functionality of the
springs while also often providing added benefits. For example, a
sculpted foam surface (e.g. foam pillars) may provide more
flexibility in adjusting to various body contours than metal
springs, and therefore may be more effective in reducing pressure
points against the human body than traditional metal springs in
conventional mattresses. More specifically, the layer(s) of foam
with a sculpted surface would typically include a plurality of foam
pillars (or blocks), each of which is freestanding (e.g.
independent) with respect to the other pillars, but all of which
are joined together into a single integral base (which typically
has a flat exterior surface). So, the base portion of the pillars
are all joined together (e.g. a common base), while the remaining
freestanding portion of the layer of foam comprise a plurality of
independent pillars separated from one another by a gap or groove
on all sides. Stated another way, the sculpted layer(s) of foam may
comprise each a base portion (which typically is a uniform flat
sheet of foam) and a pillar portion (which typically comprises a
plurality of independent pillars or blocks of foam, each of which
is completely separate from the other pillars), with the pillar
portion being securely attached to a surface of the base portion
(so in effect the pillars project out from the flat base portion).
Thus, the sculpted surface of the sculpted layer of foam would
typically be the distal surface of the pillars (or pillar portion).
Typically, the sculpted layer of foam may be formed by cutting a
pattern of grooves in one surface (which would then become the
sculpted surface) of an initially uniform (e.g. flat sheet with
constant thickness) sheet of foam, thereby forming a plurality of
foam pillars which extend out from the base portion (with the
pillar portion and the base portion integrally forming a single
layer of foam having different shapes/characteristics on opposing
sides). Thus, the sculpted layer of foam might also be termed a
contour cut layer of foam in some embodiments (since in many
embodiments the layer of foam is sculpted via cutting, for example
contour cutting). In other embodiments, it may be possible to form
the sculpted layer of foam by molding (with the mold forming the
pillar portion projecting outward from the base portion).
Typically, the substantially one entire surface of the sculpted
foam layer (e.g. the entire sculpted surface) would be entirely
comprised of such pillars (e.g. substantially the entire sculpted
surface of the sculpted foam layer would be formed of pillars),
although in other embodiments the sculpted surface might have
pillars only on a portion of the sculpted surface.
[0034] Typical mattress embodiments might have vertical pinholes
passing through (at least) the base portion of the sculpted foam
layers, and such pinholes might typically be positioned to align
with the grooves/gaps between the foam pillars (so that air could
flow continuously through the vertical pinholes and the grooves to
pass from one surface of the sculpted foam layer all the way
through to the other surface of the sculpted foam layer). In some
embodiments, the base layer of foam would comprise a foam component
having a sculpted surface (typically with pillars facing upward)
surrounded by foam edge support perimeter ails (which typically
would be solid blocks of foam encompassing the sides of the base
foam component with sculpted surface, and typically having an
uncompressed height approximately equal to the uncompressed height
of the base foam component (e.g. the upper surface of the edge
support perimeter rails would typically be approximately the same
as the uncompressed height of (e.g. flush with) the upper surface
of the foam pillars of the base foam component with sculpted
surface).
[0035] Typically, mattress embodiments would have at least one
(foam) layer located between the base sculpted foam layer (which
typically would have the sculpted surface (e.g. foam pillars)
facing upward) and the middle sculpted foam layer (which typically
would have the sculpted surface (e.g. foam pillars) facing
downward), and would have at least one (foam) layer located above
the middle sculpted foam layer (e.g. a sleep surface layer
(typically of foam) would be located atop the middle sculpted foam
layer). In some embodiments, the foam pillars of the base sculpted
foam layer would be larger (e.g. the cross-section/footprint/outer
surface of the pillars would be larger) than the foam pillars of
the middle sculpted foam layer. And as mentioned above, typically
the various (foam) layers of the mattress would each have vertical
pinholes, at least some of which would align to provide continuous
airflow from the bottom to the top of the mattress. For example, in
some embodiments all (foam) layers located above the base layer of
foam might have vertical pinholes which entirely align, even though
the base foam layer might have less vertical pinholes spaced
further apart such that only some of the pinholes in the remaining
layers align with pinholes in the base layer. Although the base
layer in some embodiments may have fewer pinholes spaced further
apart than the other layers of foam, air may be operable in some
such embodiments to move through the grooves in the base portion
(e.g. since the pinholes in the base portion may be in fluid
communication with the grooves in the base portion) to the pinholes
in the upper layers of foam which are not aligned with the pinholes
in the base layer of foam.
[0036] Typically, the sculpted layer of foam would have a plurality
of foam pillars forming the sculpted surface, and the pillars would
be configured within the sculpted foam layer and the mattress as a
whole to essentially be limited to movement only (or in some
embodiments, primarily) in the vertical direction (e.g. without any
horizontal/sideways movement of the pillars during use of the
mattress). In other words, the configuration of the foam layers of
the mattress (for example, with the layers placed in contact in
such a way as to minimize shear or torsion in the pillars during
construction (e.g. essentially placing the pillars only in
compression) and with the layers perhaps laminated together) would
typically ensure that compression on the top (e.g. sleep surface)
of the mattress would be transmitted to the foam pillars entirely
as a vertical (e.g. compression) force (without, for example,
introducing any (e.g. substantial) horizontal, shear, or torsion
forces to the foam pillars) for each affected foam pillar.
Additionally, each pillar of foam in the sculpted layer would
typically be configured for essentially independent movement (e.g.
each pillar moves independent of the other, surrounding/proximate
pillars). This independence might arise due to the contour
grooves/gaps) separating the foam pillars and/or the fact that the
base of the foam pillars would be linked by conformable foam (e.g.
in the form of an integrated base of foam linking all pillars
together). So, embodiments might have pillars of the sculpted foam
layer configured for essentially independent movement and/or
essentially only vertical movement during usage of the mattress
(e.g. by a user lying atop the mattress). Typical embodiments might
have the pillars configured for independent movement essentially
only in the vertical direction. For example, each foam pillar might
be operable to move vertically without substantially imparting any
vertical movement to surrounding/proximate foam pillars in the
sculpted foam layer. Thus, movement by one foam pillar typically
might not impart any movement to other foam pillars in proximity
within the sculpted foam layer (such that each pillar movement
would independently relate to its own loading from the sleep
surface above). So, each foam pillar of an exemplary sculpted foam
layer in a disclosed mattress embodiment may be operable to only
(or in some embodiments primarily) carry/support compression forces
from directly above the foam pillar. Of course, Applicant does not
intend to be bound by theory, but rather simply notes that the
presently-disclosed embodiments may perform/operate differently
and/or better. Such configuration of the sculpted foam layer (with
regard to movement) may be quite different from the typical
movement allowed/provided by conventional metal springs (e.g. coil
springs in a mattress). Conventional coil spring mattresses have a
series of springs which typically are linked by wire across their
top surfaces. Thus, the coil springs do not move independently
(e.g. movement by one coil spring necessarily affects the
surrounding coil springs due to the rigid nature of the linking
wire frame), and the linking wire frame at the top of the coil
springs may typically introduce non-vertical (e.g. non-compression)
forces into the springs (such that the coil springs may flex and
move horizontally and/or torsionally, for example, in response to a
user atop the mattress sleep surface). Thus, the disclosed
embodiments with foam pillars in a spring-less mattress) may
perform quite differently in operation than a conventional spring
mattress. Applicant notes that disclosed mattress embodiments
typically do not include traditional springs, but, for example,
might be termed all-foam mattresses (e.g. all the cushion/support
elements are foam) and/or (metal/coil) spring-free mattresses (e.g.
no springs, even if the mattress embodiment may include some other
cushion/support element(s) in addition to or instead of one or more
foam elements).
[0037] While typical sleep system embodiments would comprise a
mattress embodiment atop a foundation embodiment, other embodiments
might be focused on only the mattress or only the foundation. In
other words, disclosed mattress embodiments could alternatively be
used with conventional foundation elements (or even
separately/alone), and disclosed foundation embodiments could
alternatively be used with conventional mattress elements (although
doing so might reduce some potential benefits available through the
joint use of disclosed mattress embodiment(s) with disclosed
foundation embodiment(s), since the joint use of ventilation
mattress atop ventilation foundation may provide for improved fluid
communication therebetween). A preferred embodiment, however, would
typically place a mattress configured to allow airflow/air transfer
through its bottom surface and perhaps also typically having some
means of air distribution throughout the mattress (e.g. pinholes)
for air passing through the bottom surface of the mattress) atop a
foundation configured to provide airflow/air transfer (for example,
forced airflow, which might be suction and/or blowing) through its
upper surface.
[0038] Turning now to the figures for specific exemplary
embodiments, FIG. 1A illustrates exemplary embodiment(s) of a
ventilated sleep system 100 (typically comprising a mattress and a
foundation), with a ventilated mattress 140 used in conjunction
with (typically directly atop) a ventilation foundation (such as
either 120a or 120b, which basically differ regarding the location
of the airflow unit). The mattress 140 has a bottom surface 142
which allows air flow into and/or out of the mattress. For example,
the bottom surface of the mattress cover might be formed of or
comprise high airflow mesh fabric (for example, 150 gsm 100%
polyester spacer mesh fabric restricting airflow CFM less than
about 35% at 3 PSI). In some embodiments, the upper surface of the
mattress 140 might also allow airflow into/out of the mattress (for
example, with the upper surface of the mattress cover being formed
of or comprising high airflow mesh fabric, similar to that used for
the bottom surface of the mattress cover as described above).
[0039] Either foundation 120a (with an airflow unit 130a external
to the support structure of the foundation and/or cover of the
foundation, for example externally mounted on the foundation,
perhaps underneath the foundation at or near the foot end of the
bed, for example centered from side to side, and in fluid
communication with the foundation hollow cavity via
inlet/intake/opening 132a) or foundation 120b (with airflow unit
130b located within the foundation support structure and/or cover,
for example mounted internally on the bottom/base panel of the
foundation, perhaps within the foundation at or near the foot end
of the bed, for example on the left side when looking at the
foundation from the foot, and in fluid communication with the
external environment via inlet/intake/opening 132b) might
optionally be used with the mattress 140, with the mattress 140
being located atop either foundation 120a or 120b to form the
ventilated sleep system. In both foundation embodiments 120a and
120b, the upper surface of the foundation 122a or 122b respectively
would be configured to allow airflow out of the foundation (for
example, into a mattress 140 directly atop (and in contact with)
the foundation. So for example, the upper surface 122a or 122b of
the foundation cover might be formed of or comprise high airflow
mesh fabric (similar to that described above with respect to the
bottom surface of the mattress cover, for example, to allow airflow
communication between the foundation and the mattress). And
typically, the foundation might be held above the floor by a frame
or legs 111a,b (which might be similar to conventional bed frames
used for conventional box springs, for example, and which might
provide sufficient clearance from the floor to allow the required
airflow for operation of the ventilation mattress system).
Typically, the frame would not interfere with or block the
inlet/intake/opening for the airflow unit 130a,b.
[0040] So, in FIG. 1A, air might pass into the foundation 120a,b,
for example through a filter such as a HEPA filter and/or through a
climate control unit (which might, for example, be operable to cool
and/or heat the air) via an airflow unit 130a,b, passing through
the foundation (e.g. hollow cavity) to exit through the upper
surface 122a,b of the foundation and enter the bottom surface 142
of the mattress 140 in order to pass (vertically) through at least
a portion of the mattress 140. In such a system, the airflow unit
130a,b might pump air into the mattress through the foundation.
Alternatively, air might flow through the system in reverse, with
the airflow unit sucking air out of the mattress and into the
foundation (and then out to the external environment). The airflow
unit typically might displace about 100-300 CFM, and typically
might operate at less than about 6 dB.
[0041] In some embodiments, the upper surface of the mattress 140
might also allow for airflow (for example, being formed of or
comprising high airflow mesh or loosely woven fabric panels,
similar to those previously described). In some embodiments, the
high airflow fabric panels throughout the sleep system (or at least
for the upper foundation cover surface and lower mattress cover
surface) might all be similar and/or formed of the same material.
In some embodiments, a fabric material with sufficiently loose
weave may allow the desired airflow between the foundation and the
mattress and serve as the foundation air permeable element(s)
and/or the mattress air permeable member(s). In other embodiments,
the air permeable elements/members may be formed of any variety of
sufficiently porous material. In some embodiments, the airflow unit
130a,b might be configured to allow for forward and reverse
operation (e.g. operable to allow air to be blown into or sucked
out of the mattress by the foundation). The arrows in FIG. 1A
illustrate potential airflow in the system, as persons of skill
would understand.
[0042] Typically, the foundation(s) 120a,b of FIG. 1A would
comprise a hollow structure (with a cavity) (formed, for example,
by support struts and a structural frame), and air would be pumped
into/out of the hollow structure cavity (for example, by the
airflow unit 130a,b). In other words, in such embodiments, air
would simply flow through the hollow cavity of the foundation as it
interacts with the mattress and the outside environment. So for
example, external air might be drawn into the hollow cavity of the
foundation through the inlet/intake/opening 132a,b, flow through
the hollow cavity to the upper surface of the foundation 122a,b,
flow out of the foundation through the upper surface 122a,b and
into the mattress through the mattress bottom 142, and then pass
through at least a portion of the mattress 140 (and in some
embodiments, air might flow all the way through the mattress and
optionally might flow out the upper surface of the mattress).
Alternatively, air might flow into the hollow cavity of the
foundation 120a,b through the upper surface 122a,b (for example,
sucking air from the mattress 140 through the bottom surface 142 of
the mattress), through the hollow cavity of the foundation, and out
of the foundation 120 via inlet/intake (which in this case would
actually serve as an outtake)/opening 132a,b to the external
environment.
[0043] FIG. 1B illustrates an alternative embodiment sleep/bedding
system, similar to that of FIG. 1A. One version of the foundation
120b of FIG. 1B may have an access panel 132, which, for example,
might allow for easy access to change the HEPA filter and/or to
provide maintenance or repair to the airflow unit 130b. FIGS.
1Ca-1Cc illustrate in more detail an exemplary sleep/bedding system
embodiment similar to FIG. 1B, having an internal (e.g.
mounted/located within the foundation frame/cover) airflow unit
130b, with FIG. 1Ca showing a side view, FIG. 1Cb showing an end
view of the foot of the bed, and FIG. 1Cc showing a top view.
Typically, in the embodiment of FIGS. 1Ca-1Cc, the airflow unit
130b might be located at (e.g. in proximity to) the foot of the bed
within the foundation. For example, the optional HEPA filter might
be located over the air intake, with air then flowing through the
blower to be expelled into the hollow cavity of the foundation. In
some embodiments, there may be an access panel, for example located
on the upper surface of the foundation above the HEPA filter or air
intake or airflow unit. The access panel might be a hinged section
(for example, operable to open by pivoting upward) of the upper
foundation surface (although in some embodiments, the access panel
portion of the upper foundation cover might not be air permeable,
for example to help direct air through the blower and into the
foundation).
[0044] FIGS. 1Da-1Dc illustrate in more detail an exemplary
sleep/bedding system embodiment similar to FIG. 1B, having an
external (e.g. mounted/located outside the foundation frame/cover,
for example mounted beneath the foundation) airflow unit 130a, with
FIG. 1Da showing a side view, FIG. 1Db showing an end view of the
foot of the bed, and FIG. 1Dc showing a top view. Typically, the
airflow unit 130a of FIGS. 1Da-1Dc might be mounted to the bottom
surface of the foundation at or in proximity to the foot of the bed
(perhaps located towards the center between the sides). And again,
there may be an access panel, which, for example, might typically
be located on the housing of the airflow unit to allow access to
the HEPA filter and/or blower. FIG. 1E illustrates an exemplary
sleep/bedding system in 3D perspective view, showing that
externally the sleep/bedding system would resemble a conventional
mattress atop a conventional box-spring foundation unit (e.g. a
typical conventional bed).
[0045] FIGS. 2A1 and 2A2 illustrate an exemplary ventilation
mattress 240A, which is an all-foam (or spring-free) mattress
formed of a plurality of foam layers (with the base layer being a
sculpted foam layer having the sculpted surface (with foam pillars)
facing upward, a middle sculpted foam layer having the sculpted
surface (with foam pillars) facing downward, a sleep surface layer,
at least one foam layer (e.g. transition layer) between the middle
sculpted foam layer and the base sculpted foam layer, and/or a foam
layer located between the sleep surface layer and the middle
sculpted foam layer). While FIG. 2A1 shows the foam components of
the mattress (e.g. with the cover removed) in perspective view,
FIG. 2A2 shows a side cross-section view of the same mattress.
FIGS. 2B1 and 2B2 illustrate a similar all foam mattress (e.g. with
the foam components removed from the cover), and differs primarily
in the particular foam material selected (with the embodiment of
FIG. 2A1 being formed of conventional high density foam (e.g. all
component foam layers are formed of conventional high density
foam), and the embodiment of FIG. 2B1 having the top two layers
formed of memory foam, for example gel memory foam, while the
remaining layers are formed of conventional high density foam). And
in some embodiments, all such foam layers would be adhered into an
integrated whole (e.g. laminated) and/or enclosed/encased in a
cover, thereby forming an integrated mattress.
[0046] So in FIG. 2A1, the mattress 240A comprises a base layer of
foam 242 (which comprises a sculpted foam element with the sculpted
surface (e.g. the foam pillars) facing/extending upward) located as
the bottom layer of foam in the mattress, a middle sculpted foam
layer 250 with the sculpted surface (e.g. foam pillars)
facing/projecting downward and located above the base layer
(although typically not directly above or in contact with the base
layer), a transition foam layer 260 located between (and typically
in contact with) the base layer of sculpted foam 242 and the middle
sculpted foam layer 250, a top/sleep surface layer of foam 270
(typically located as the uppermost foam layer in the mattress),
and (optionally) a second (e.g. penultimate) layer of foam 280
located between the sleep surface layer 270 and the middle sculpted
foam layer 250. FIG. 2A1 shows the layers of foam of the mattress
240A without the cover (not shown), illustrating the order and
orientation of the foam layers in this mattress embodiment.
Typically, the foam layers are arranged one atop another in the
order described above, with proximate layers contacting one another
(e.g. the base layer 242 is the bottom layer, the transition layer
260 is located atop and in contact with the base layer, the middle
sculpted foam layer 250 is located atop and in contact with the
transition layer, the second (penultimate) layer 280 is located
atop and in contact with the middle sculpted foam layer, and the
top (sleep surface) layer 270 is located atop and in contact with
the second (penultimate) layer and forms the upper foam layer of
the mattress 240A). Typically, the layers would all be encased
within a cover (not shown here), and typically the cover would have
a bottom surface with means for airflow (for example, one or more
panels of high airflow mesh fabric). Also, in some embodiments, the
upper surface of the cover might include means for airflow (for
example, an air permeable element, such as one or more panels of
high airflow mesh fabric).
[0047] In FIG. 2A1, the base layer comprises a sculpted foam
element/layer 243 with upward facing sculpted surface (e.g. foam
pillars 248 projecting upward and separated by a series grid) of
gaps or grooves or cuts 247), and edge perimeter rails of foam 244
which surround/encase the sculpted foam element 243 on all sides
(e.g. about/around the perimeter of the sculpted foam element 243).
Typically, the edge support perimeter rails 244 might be formed of
the same foam as the base layer sculpted foam element 243 and/or
might have the same uncompressed height as the sculpted foam
element 243 (e.g. the upper surface of the edge support perimeter
ails 244 might be approximately level with the upper surface of the
foam pillars 248 of the sculpted foam element 243 when both are
uncompressed). In the embodiment of FIG. 2A1, the foam pillars 248
would typically have a square rectangular outer surface (and/or
cross-section) of about 4 inches by 4 inches, and the gaps/grooves
247 forming the grid resulting in the foam pillars might typically
have a width of about 0.75 inches and a depth of about 3 inches.
So, for example, the gaps/grooves in the base layer might typically
have a depth ranging from about 1/2 to 2/3 the total height for the
base layer, for example about 60% in some exemplary embodiments. In
addition, the joined bases of the foam pillars of the sculpted foam
element 243 typically would have a plurality of pinholes (e.g.
essentially vertical air passageways), as will be described in
greater detail below. In alternate embodiments, the pinholes might
pass through both the base portion and the pillar portion of one or
more of the sculpted foam layers.
[0048] In FIG. 2A1, the transition foam layer 260 would typically
be a flat sheet of foam with a plurality of pinholes 265 (e.g.
essentially vertical air passageways). In the embodiment of FIG.
2A1, the transition layer 260 would typically have the same width
and length dimensions (e.g. depending on whether the mattress is a
twin, full/double, queen, king, etc.) as the base layer 242 (e.g.
including both the sculpted foam element 243 and the surrounding
edge support perimeter rails 244), although in other embodiments
(in which the foam pillars are lower than the surrounding edge
support perimeter rails, for example by a height approximately
equal to the thickness of the transition layer, the transition
layer 260 might be sized to fit over just the sculpted foam element
243 of the base layer 242 (e.g. so that it would be located within
the edge support perimeter rails 244 as well).
[0049] The middle sculpted foam layer 250 of FIG. 2A1 would
typically be sized (e.g. width and length) approximately the same
as the base layer 242 and/or the transition layer 260 (and
typically the same as the layers atop it as well), and would be
oriented with the sculpted surface (e.g. foam pillars 258)
facing/projecting downward. In the embodiment of FIG. 2A1, the foam
pillars 258 would typically have a square rectangular outer surface
(and/or cross-section) of about 2 inches by 2 inches, and the
gaps/grooves 257 forming the grid resulting in the foam pillars
might typically have a width of about 0.375 inches and a depth of
about 1.75 inches. So for example, the gaps/grooves in the middle
sculpted layer might typically have a depth ranging from about 1/2
to 2/3 the total height for the middle sculpted layer, for example
about 55-60% in some exemplary embodiments. In addition, the joined
bases of the foam pillars of the middle sculpted layer 250
typically would have a plurality of pinholes 255 (e.g. essentially
vertical air passageways), as will be described in greater detail
below. Typically, the pinholes 255 of the middle sculpted foam
layer 250 would be spaced and/or oriented/located the same
(identically) as the pinholes 265 in the transition foam layer 260
(and typically also the same as the layers located above it), with
the pinholes 255 aligning vertically with the pinholes 265. And
typically, at least some of the pinholes 255/265 would also align
with the pinholes 245 in the base layer 242 (e.g. the sculpted foam
element 243 of the base layer). For example, every other pinhole
255,265 might align with a pinhole 245 (and groove/gap 247) in the
sculpted foam element of the base layer. In some embodiments, the
middle sculpted foam layer might also (or instead) comprise an
upper surface that is sculpted (for example, with foam pillars
formed by a grid of grooves, as discussed earlier).
[0050] The second (penultimate) foam layer 280 and the upper (sleep
surface) foam layer 270 would typically each be a flat sheet of
foam with a plurality of pinholes 285, 275 respectively (e.g.
essentially vertical air passageways). In the embodiment of FIG.
2A1, both the second (penultimate) foam layer 280 and the upper
(sleep surface) foam layer 270 would typically have the same width
and length dimensions (e.g. depending on whether the mattress is a
twin, full/double, queen, king, etc.) as the base layer 242, the
transition layer 260, and/or the middle sculpted layer 250. And,
the pinholes 285, 275 of the second (penultimate) foam layer 280
and the top (sleep surface) layer 270 respectively would typically
be spaced and/or oriented/located the same (identically) as the
pinholes 265 in the transition foam layer 260 and the pinholes 255
in the middle sculpted foam layer 250, with the pinholes 285, 275
aligning vertically with the pinholes 265, 255. Thus, the pinholes
265, 255, 285, and 275 of FIG. 2A1 would typically align to form
continuous airflow pathways from the upper surface of the base
layer upward to the upper surface of the mattress (although in
other embodiments, only some of the pinholes might align). And
typically, at least some of the pinholes 285/275 would also align
with the pinholes 245 in the base layer 242 (e.g. the sculpted foam
element 243 of the base layer). For example, every other pinhole
285,275 might align with a pinhole 245 (and groove/gap 247) in the
sculpted foam element of the base layer. In other embodiments, the
pinholes 265, 255, 285, and 275 might all align with the pinholes
245 in the base layer (e.g. the pinholes in all the layers could be
spaced equally so they all align to form continuous airflow
pathways from the bottom surface of the mattress to the upper
surface of the mattress).
[0051] Similarly, FIG. 2A2 shows a cross-section view of the foam
elements of the mattress 240A shown in FIG. 2A1. In this
embodiment, the base layer 242 typically would have an uncompressed
height of about 5 inches, the transition layer 260 typically would
have an uncompressed height of about 1.25 inches, the middle
sculpted foam layer 250 typically would have an uncompressed height
of about 3 inches, the second (penultimate) foam layer 280
typically would have an uncompressed height of about 1.75 inches,
and the top (sleep surface) layer 270 typically would have an
uncompressed height of about 1.25 inches. In FIG. 2A2, the foam
layers would typically vary in firmness, from softest at the top to
hardest/firmest at the bottom. For example, the top (sleep surface)
layer 270 would typically be the softest layer of foam (for
example, IFD of about 14), the second (penultimate) layer 280 would
typically be somewhat firmer that the top layer (for example, IFD
of about 20), the middle sculpted foam layer 250 would typically be
somewhat firmer than the second (penultimate) layer (for example,
IFD of about 35), the transition layer 260 typically would be what
firmer than the middle sculpted layer (for example, IFD of about
45), while the base layer 242 might typically have the same
firmness as the transition layer (for example, IFD of about 45). In
other embodiments, the base layer 242 might be somewhat firmer than
then transition layer 260. Typically, the edge support perimeter
rails 244 would have the same firmness (e.g. IFD) and/or be formed
of the same foam as the sculpted foam element 243 of the base
layer. In other embodiments, the firmness of the various layers may
differ and/or may vary differently from the descriptions above. And
in FIG. 2A2, the thickness (e.g. lateral width) of the edge support
perimeter rails typically would be about 4 inches (or in other
embodiments, about the same size as one of the foam pillar's 248
square rectangular outer surface (and/or cross-section) sides).
[0052] FIG. 2A2 also shows the alignment of the pinholes 265, 255
(and gap 257), 285, and 275, and the fact that every other pinhole
265, 255, 285, 275 aligns with a pinhole 245 (and gap 247) of the
base layer 242 in this embodiment. The alignment of pinholes may
allow continuous airflow upward from the bottom surface of the
mattress to the upper surface of the mattress 240A and/or downward
from the upper surface of the mattress to the bottom surface of the
mattress, as illustrated by the exemplary airflow arrows (except
along the perimeter edges where the edge support perimeter rails
may not have pinholes, in some embodiments). In some embodiments,
the pinholes may be hole punched into the foam sheets/layers, while
in other embodiments the pinholes might be formed, for example, by
molding of the foam sheets/layers). And in some embodiments, the
gaps/grooves 247, 257 might be cut/scored into the foam to form the
sculpted surface(s), while in other embodiments the gaps/grooves
might be formed, for example, by molding (e.g. due to the shape of
the foam mold forming the layer(s)). The upper surface of the top
layer of foam 270 forms the sleep surface 272 (although typically
there would be a cover, not shown here, lying atop/encasing the
foam).
[0053] So in some embodiments, the mattress might comprise at least
two sculpted foam layers (with each having a sculpted surface with
a plurality of pillars) with a transition foam layer (and typically
only one such transition foam layer) therebetween. The upper
sculpted foam layer would typically be oriented with its sculpted
surface facing downward (although in other embodiments, it could
face upward and/or there might not be a foam (transition) layer
between the two sculpted foam layers), while the lower/bottom
sculpted foam layer (e.g. the base layer) would typically be
oriented with its sculpted surface facing upward. And typically
(although optionally), there would be one or more foam layers
located above the uppermost sculpted foam layer (e.g. the middle
sculpted foam layer), with these top foam layers having a softer
IFD than that of the middle sculpted foam layer. A series of
pinholes in the foam layers (perhaps in conjunction with the
gaps/grooves forming the sculpted surface of the sculpted foam
layers) would allow for airflow vertically throughout the mattress
(or at least through a plurality of foam layers of the mattress).
And typically, the foam layers would be enclosed/encased within a
cover, which typically would have a bottom/lower surface which is
air permeable (for example, formed of or comprising high airflow
mesh fabric, typically allowing airflow comparable to the upper/top
surface of the ventilation foundation upon which such a mattress
would typically operate). So as discussed above, the mattress
embodiment would typically have a bottom cover surface allowing
airflow therethrough (e.g. one or more panels restricting airflow
cubic feet per minute less than about 35% at 3 PSI), and the
ventilation foundation (upon/atop which the mattress embodiment
would typically be used) typically would also have an upper/top
cover surface allowing airflow therethrough (for example, similar
to the airflow allowed by the bottom surface of the cover of the
mattress), such that the joint mattress-foundation sleep/bedding
system embodiment typically would effectively allow airflow between
the foundation and the mattress (for example, based on an airflow
unit in or on the foundation).
[0054] FIGS. 2B1 and 2B2 show a similar foam mattress 240B formed
of multiple layers of foam (typically within a cover (not shown)).
The embodiment of FIGS. 2B1 and 2B2 is substantially the same in
structure as the embodiment of FIGS. 2A1 and 2A2, primarily
differing in the foam material used. For example, in FIG. 2B1, the
top two layers might be memory foam (for example, gel memory foam).
Persons of skill will understand that the foam materials and/or
characteristics of the layers of foam for such exemplary mattresses
may differ, for example being selected based on the specific needs
of the particular mattress.
[0055] FIG. 3 illustrates an exemplary base foam layer 242 (similar
to that of FIG. 2A1, for example), showing the sculpted surface
(e.g. upper surface) of the sculpted foam element 243 (with foam
pillars 248 separated by gaps/grooves 247 in a grid) and the edge
support perimeter rails 244 in plan view (of the upper, sculpted
surface). As noted above, the foam edge support rails 244 surround
and abut all four sides of the sculpted foam element 243, and they
each may typically have a width (e.g. lateral dimension)
approximately equal to one of the sides of the square rectangular
outer surface (and/or cross-section) of the foam pillars 248.
Typically (as shown in FIG. 3), all of the foam pillars 248 would
be equally sized (for example, they might all be equally sized with
a square cross-section, as, for example, formed by a grid of
grooves/gaps 247 in which the longitudinal grooves/gaps 247 are
equally spaced, and the lateral gaps/grooves are also equally
spaced apart by the same amount as the longitudinal gaps, for
example forming a grid that resembles a checkerboard). So, for
example, in the embodiment of FIG. 3, the foam pillars 248 would
typically have a square rectangular outer surface (and/or
cross-section) of about 4 inches by 4 inches, and the gaps/grooves
247 forming the grid resulting in the foam pillars might typically
have a width of about 0.75 inches and a depth of about 3
inches.
[0056] FIG. 3 also shows the pinholes 245 in the base layer, which
are typically located in the joined base portion of the foam
pillars of the base layer so that they exit into the gaps/grooves
247 separating the foam pillars 248. In other words, the pinholes
245 typically do not pass through the projecting foam pillar
portion of the base layer sculpted foam element 243, but rather
pass only though the integral base portion of the sculpted foam
element 243 (e.g. the bottom portion where the foam pillars are
joined together into an integral whole) such that the pinholes
extend upward from the bottom of the base layer 242 to exit within
the gaps/grooves 247 between the foam pillars 248. The pinholes 245
of FIG. 3 typically might have a diameter of about 0.5 inches (and
typically would all be about the same size), and typically would be
spaced apart approximately 3.937 inches. So, for example, the
pinholes 245 typically might be located within the gaps/grooves 247
at locations in proximity to the corners of each foam pillar 248 of
the base layer 242.
[0057] Similarly, FIG. 4 illustrates an exemplary middle sculpted
surface layer 250 (similar to that of FIG. 2A1, for example),
showing the sculpted surface (e.g. the bottom surface) (with foam
pillars 258 separated by gaps/grooves 257 in a grid) in plan view
(of the sculpted surface). Typically (as shown in FIG. 4), all of
the foam pillars 258 would be equally sized (for example, they
might all be equally sized with a square cross-section, as, for
example, formed by a grid of grooves/gaps 257 in which the
longitudinal grooves/gaps 257 are equally spaced, and the lateral
gaps/grooves are also equally spaced apart by the same amount as
the longitudinal gaps, for example forming a grid that resembles a
checkerboard). So, for example, in the embodiment of FIG. 4, the
foam pillars 258 would typically have a square rectangular outer
surface (and/or cross-section) of about 2 inches by 2 inches, and
the gaps/grooves 257 forming the grid resulting in the foam pillars
might typically have a width of about 0.375 inches and a depth of
about 1.75 inches. While the embodiment of FIG. 2A1, for example,
has the foam pillars 258 of the middle sculpted foam layer sized to
be about 1/4 the size of the foam pillars 248 of the base layer
(e.g. 2 inches by 2 inches versus 4 inches by 4 inches, such that
each 4.times.4 pillar in the base layer of FIG. 2A1, for example,
might have four 2.times.2 pillars in the middle sculpted layer
located above it), in other embodiments, the ratio of the foam
pillar sizing may vary (for example, the foam pillars 258 could be
the same size as the foam pillars 248 in some embodiments, or the
foam pillars 258 might be 1/2, 1/3, 1/8, or 1/16 the size of the
foam pillars 248 in other embodiments). Typically, the sizing ratio
would be such that at least some of the gaps/grooves 257 in the
middle sculpted foam layer would align with at least some of the
gaps/grooves 247 of the base layer (since that may be important to
aid in alignment of pinholes in some embodiments, as well as
perhaps providing consistent support and/or comfort
characteristics).
[0058] FIG. 4 also shows the pinholes 255 in the middle sculpted
layer, which are typically located in the joined base portion of
the foam pillars 258 of the middle sculpted layer so that they exit
into the gaps/grooves 257 separating the foam pillars 258. In other
words, the pinholes 255 typically do not pass through the
projecting foam pillar portion of the middle sculpted foam layer,
but rather pass only through the integral base portion of the
middle sculpted layer 250 (e.g. the bottom portion where the foam
pillars are joined together into an integral whole) such that the
pinholes 255 extend downward from the top of the middle sculpted
layer 250 to exit within the gaps/grooves 257 between the foam
pillars 258. The pinholes 255 of FIG. 4 typically might have a
diameter of about 0.25 inches (and typically would all be about the
same size), and typically would be spaced apart approximately
1.9685 inches. So for example, the pinholes 255 typically might be
located within the gaps/grooves 257 at locations in proximity to
the corners of each foam pillar 258 in the middle sculpted layer
250. As discussed above, the pinholes in the foam layers (of an
exemplary mattress) above the middle sculpted layer (as well as
perhaps an underlying transition layer) typically would be sized
and spaced (e.g. located) identical to those in the middle sculpted
layer, in order to form continuous airflow pathways upward.
[0059] For additional details that may be relevant for some
embodiments (particularly some mattress embodiments and/or systems
having mattress embodiments), U.S. patent application Ser. No.
14/681,278 (entitled "Independent Foam Spring Mattress" and filed
Apr. 8, 2015, along with related provisional patent application
Ser. No. 61/977,989 entitled "Independent Foam Spring Mattress" and
filed Apr. 10, 2014) is hereby incorporated by reference for all
purposes as if reproduced in its entirety to the extent that it is
compatible (e.g. not inconsistent) with and/or does not directly
contradict disclosure herein (e.g. the explicit disclosure herein
would always govern/trump in instances of contradiction,
inconsistency, or incompatibility). Specifically, details about the
foam layers and/or formation of the foam layers from the
incorporated by reference U.S. patent applications might be used in
some embodiments (for example, within a mattress cover as described
herein).
[0060] Having described above various embodiments (especially those
explicitly shown in the figures), various additional embodiments
may include, but are not limited to, the following:
[0061] In a first embodiment, a mattress foundation comprising a
support structure; an airflow unit; and a foundation cover for the
support structure comprising an upper surface, and wherein the
upper surface comprises an air permeable element. In a second
embodiment, the foundation of the first embodiment wherein the
foundation cover encases the support structure to form a hollow
cavity; wherein the foundation cover further comprises one or more
port allowing fluid communication between the hollow cavity and the
outside environment; and wherein the airflow unit is configured to
induce fluid flow between the hollow cavity and the outside
environment via the one or more port. In a third embodiment, the
foundation of embodiments 1-2 wherein the air permeable element
comprises one or more high airflow mesh fabric panels. In a fourth
embodiment, the foundation of embodiments 1-3 wherein the entire
upper surface of the foundation cover is formed of high airflow
mesh fabric. In a fifth embodiment, the foundation of embodiments
1-4 wherein the one or more port is located on a bottom surface of
the foundation cover. In a sixth embodiment, the foundation of
embodiments 1-5 wherein the airflow unit is located within the
support structure. In a seventh embodiment, the foundation of
embodiments 1-6 wherein the airflow unit is located within the
hollow cavity over the port. In an eighth embodiment, the
foundation of embodiments 1-7, wherein the airflow unit comprises a
HEPA filter. In a ninth embodiment, the foundation of embodiments
1-8 wherein the airflow unit comprises a climate control unit
operable to cool or heat air. In a tenth embodiment, the foundation
of embodiments 1-9 wherein the cover is air impermeable except for
the upper surface and the one or more port. In an eleventh
embodiment, a sleep system comprising a foundation as in
embodiments 1-10 and a mattress, wherein the mattress is located
atop and in contact with the foundation and wherein the mattress
and foundation are in fluid communication with each other. In a
twelfth embodiment, the sleep system of embodiment 11 wherein the
mattress comprises a mattress cover encompassing the mattress (e.g.
encompassing/enveloping the support elements--such as springs
and/or foam by way of non-exclusive example); wherein the mattress
cover comprises a bottom surface, and wherein the bottom surface
comprises a mattress air permeable member. In a thirteenth
embodiment, the sleep system of embodiments 11-12 wherein the
mattress air permeable member comprises one or more high airflow
mesh fabric panels. In a fourteenth embodiment, the sleep system of
embodiments 11-13 wherein the mattress cover further comprises an
upper surface, and wherein the upper surface comprises a second
mattress air permeable member. In a fifteenth embodiment, the sleep
system of embodiments 11-14 further comprising one or more foam
layers within the mattress cover; wherein the one or more foam
layers each comprises a plurality of vertical air pathways which
pass through the entire thickness of the corresponding foam layer.
In a sixteenth embodiment, the sleep system of embodiments 11-15
wherein the mattress comprises a plurality of foam layers; and
wherein at least some of the vertical air pathways in the foam
layers align to provide continuous airflow paths from the bottom
surface of the mattress to an upper surface of the mattress. In a
seventeenth embodiment, the sleep system of embodiments 11-16
wherein the foundation cover encases the support structure to form
a hollow cavity; wherein the foundation cover further comprises one
or more port allowing fluid communication between the hollow cavity
and the outside environment; and wherein the airflow unit is
configured to induce fluid flow between the hollow cavity and the
outside environment via the one or more port. In an eighteenth
embodiment, the sleep system of embodiments 11-17 wherein the one
or more port is located on a bottom surface of the cover; and
wherein the airflow unit is located within the hollow cavity. In a
nineteenth embodiment, the sleep system of embodiments 11-18
wherein the airflow unit comprises a HEPA filter; and wherein the
airflow unit comprises a climate control unit. In a twentieth
embodiment, the sleep system of embodiments 11-19 wherein the one
or more foam layers of the mattress (for example for an all-foam
mattress and/or a metal spring-free mattress) comprise a base layer
of foam comprising a sculpted upper surface (e.g. having a
plurality of foam pillars projecting upward (for example, with the
foam pillars formed by a grid pattern of gaps/grooves in the upper
surface of the base layer of foam)); a transition layer of foam
(which typically is a uniform thickness (e.g. flat) sheet/slab of
foam) located atop and in contact with the upper surface of the
base foam layer; a middle sculpted layer of foam having a sculpted
lower surface (e.g. having a plurality of foam pillars projecting
downward (for example, with the foam pillars formed by a grid
pattern of gaps/grooves in the lower surface of the middle sculpted
layer of foam)), wherein the middle sculpted layer of foam is
located atop and in contact with the transition layer of foam; and
a top (sleep surface) layer of foam (which typically is a uniform
thickness (e.g. flat) sheet/slab of foam) located above the middle
sculpted layer. In a twenty-first embodiment, the sleep system of
embodiments 11-20 wherein the one or more foam layers further
comprises a second (penultimate) foam layer (which typically is a
uniform thickness (e.g. flat) sheet/slab of foam) located atop and
in contact with the middle sculpted layer and beneath and in
contact with the top (sleep surface) layer of foam. In a
twenty-second embodiment, the sleep system of embodiments 11-21
wherein the foundation is operable/configured to suck air out of
the mattress (such that air flows out of the mattress through the
bottom surface of the mattress cover (e.g. through the one or more
high airflow mesh fabric panels), into the foundation through the
upper surface of the foundation cover (e.g. through the one or more
high airflow mesh fabric panels), and out to external environment
via the airflow unit/opening/port. In a twenty-third embodiment,
the sleep system of embodiments 11-22 wherein the foundation is
operable/configured to blow air into the mattress (such that air is
drawn into the hollow cavity of the foundation by the airflow unit,
out of the foundation through the upper surface of the foundation
cover (e.g. through the one or more high airflow mesh fabric
panels), into the mattress through the bottom surface of the
mattress cover (e.g. through the one or more high airflow mesh
fabric panels); (and optionally, out the mattress through the upper
surface of the mattress cover (e.g. through the one or more
optional high airflow mesh fabric panels). In a twenty-fourth
embodiment, the sleep system of embodiments 11-23 wherein the
support structure further comprises legs operable to hold the
foundation above a floor (e.g. at a sufficient height to allow for
effective airflow). In a twenty-fifth embodiment, the sleep system
of embodiments 11-24 wherein the middle sculpted layer of foam
further comprises a sculpted upper surface (e.g. having a plurality
of foam pillars projecting upward (for example, with the foam
pillars formed by a grid pattern of gaps/grooves in the upper
surface of the middle sculpted layer of foam)).
[0062] While various embodiments in accordance with the principles
disclosed herein have been shown and described above, modifications
thereof may be made by one skilled in the art without departing
from the spirit and the teachings of the disclosure. The
embodiments described herein are representative only and are not
intended to be limiting. Many variations, combinations, and
modifications are possible and are within the scope of the
disclosure. Alternative embodiments that result from combining,
integrating, and/or omitting features of the embodiment(s) are also
within the scope of the disclosure. Accordingly, the scope of
protection is not limited by the description set out above, but is
defined by the claims which follow, that scope including all
equivalents of the subject matter of the claims. Each and every
claim is incorporated as further disclosure into the specification
and the claims are embodiment(s) of the present invention(s).
Furthermore, any advantages and features described above may relate
to specific embodiments, but shall not limit the application of
such issued claims to processes and structures accomplishing any or
all of the above advantages or having any or all of the above
features.
[0063] Additionally, the section headings used herein are provided
for consistency with the suggestions under 37 C.F.R. 1.77 or to
otherwise provide organizational cues. These headings shall not
limit or characterize the invention(s) set out in any claims that
may issue from this disclosure. Specifically and by way of example,
although the headings might refer to a "Field," the claims should
not be limited by the language chosen under this heading to
describe the so-called field. Further, a description of a
technology in the "Background" is not to be construed as an
admission that certain technology is prior art to any invention(s)
in this disclosure. Neither is the "Summary" to be considered as a
limiting characterization of the invention(s) set forth in issued
claims. Furthermore, any reference in this disclosure to
"invention" in the singular should not be used to argue that there
is only a single point of novelty in this disclosure. Multiple
inventions may be set forth according to the limitations of the
multiple claims issuing from this disclosure, and such claims
accordingly define the invention(s), and their equivalents, that
are protected thereby. In all instances, the scope of the claims
shall be considered on their own merits in light of this
disclosure, but should not be constrained by the headings set forth
herein.
[0064] Use of broader terms such as comprises, includes, and having
should be understood to provide support for narrower terms such as
consisting of consisting essentially of, and comprised
substantially of. Use of the terms "optionally," "may," "might,"
"possibly," and the like with respect to any element of an
embodiment means that the element is not required, or
alternatively, the element is required, both alternatives being
within the scope of the embodiment(s). Also, references to examples
are merely provided for illustrative purposes, and are not intended
to be exclusive.
[0065] While several embodiments have been provided in the present
disclosure, it should be understood that the disclosed systems and
methods may be embodied in many other specific forms without
departing from the spirit or scope of the present disclosure. The
present examples are to be considered as illustrative and not
restrictive, and the intention is not to be limited to the details
given herein. For example, the various elements or components may
be combined or integrated in another system, or certain features
may be omitted or not implemented.
[0066] Also, techniques, systems, subsystems, and methods described
and illustrated in the various embodiments as discrete or separate
may be combined or integrated with other systems, modules,
techniques, or methods without departing from the scope of the
present disclosure. Other items shown or discussed as directly
coupled or communicating with each other may be indirectly coupled
or communicating through some interface, device, or intermediate
component, whether electrically, mechanically, or otherwise. Other
examples of changes, substitutions, and alterations are
ascertainable by one skilled in the art and could be made without
departing from the spirit and scope disclosed herein.
* * * * *